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New Technologies at SEMICON West 2006

Staff -- Semiconductor International, 6/15/2006

Sidebars:
International Technology Roadmap for Semiconductors (ITRS) Conference
Executive Viewpoints

SEMICON West 2006 is being held in San Francisco July 10-14 at the Moscone Center. The exhibits, which run July 11-13, are open 10 a.m.-6 p.m. on Tuesday and Wednesday, but cut off at 4 p.m. on the final day.

The show has always been a good place to catch up on the latest technology available from equipment and materials suppliers serving the semiconductor industries and related industries, such as MEMS, optoelectronics, flat panel displays and now fuel cells and solar power. It's also been a good place to get a sense of present business conditions.

In this special issue of Semiconductor International, we've focused on the technology behind the show. In the following pages, you'll get an overview of all the key areas of semiconductor manufacturing technology: nanotechnology; front-end processing; lithography; yield management; design for manufacturing; metrology; clean processing; interconnects; test, assembly and packaging; and factory automation. We've also highlighted noteworthy events in and around the show, and included comments on technology and business trends by various company executives.

Several keynote speeches have been lined up to take place during SEMICON West. Wally Rhines from Mentor Graphics will commence the keynotes at the SEMI Market Symposium on Monday. Laurent Bosson, Jim Healy and Steve Anderson from STMicroelectronics, LogicVision and Surfect Technologies, respectively, will address attendees on Tuesday, and on Wednesday, Williem Roelandts from Xilinx and Steve Appleton from Micron will speak.

We haven't tried this out yet, but SEMI is also providing attendees with a new web-based tool called SEMICONNECT. Billed as a personal assistant, the tool has intelligent matching, an event search, online introductions and interactive event planner. Check this out at https://semiconwest.bdmetrics.com/portal/eventlogin.aspx.

You can even generate a "trip justification report" if your boss thinks you want to go San Francisco in July just to cool off!

Play new video games on the XBox 360 in a Microsoft arcade, take a ride on a Segway, tip some suds in a beer hall, or see the latest fuel-cell cars and filling station. Those are all possible at this year's show as part of the newly featured TechXPOTs (pronounced "tech spots").

There will be four TechXPOTs at SEMICON West 2006:

  • Emerging Technologies: MEMS/Nanotechnology/Energy Applications — West Hall, Level 3
  • Test, Assembly and Packaging — West Hall, Level 2
  • Manufacturing Productivity and Effectiveness (EDA/e-manufacturing) — Esplanade Hall
  • Challenges in Device Scaling to 45 and 32 nm — North Hall

"Each of these TechXPOTs will have a slightly different twist, but essentially they are designed to be shows within a show," said Lubab Sheet, senior director, nanotechnology. "These TechXPOTs are really providing increased emphasis on key technology segments and key trends. All of them have exhibits, all of them have a stage with great content that is included in registration fees — some have displays that highlight technology. Some also integrate the technology innovation product showcase winners."

The Manufacturing Productivity and Effectiveness TechXPOT, for example, offers targeted content and sessions highlighting significant issues and innovations in electronic design collaboration and manufacturing productivity. "The themes covered in our Manufacturing Productivity and Effectiveness TechXPOT are critical to the continued success of device manufacturers," said John Ellis, senior director of technology and standards at SEMI. "As manufacturers strive for first-pass success on product designs, they are looking for every avenue to improve yield and shorten cycle time. Solutions found through design for manufacturing, advanced process and equipment control, and e-Manufacturing are fundamental to improving the performance of our fabs."

The Manufacturing Productivity and Effectiveness TechXPOT will feature technical sessions from industry partners such as Silicon Integration Initiative (Si2), the Advanced Equipment Control/Advanced Process Control (AEC/APC) Symposium, Sematech, and the International Sematech Manufacturing Initiative (ISMI). Exhibitors will also be providing focused technical presentations on the stage. Highlights for the hall include the TechXPOT stage featuring winners of the Technology Innovation Showcase competition (TIS); a hands-on video arcade sponsored by Microsoft featuring the semiconductor innovations used in the XBox360; a wireless hot-spot for attendees; and a special area set aside as meeting rooms for device manufacturers.

Si2 will present sessions on design for manufacturing and collaboration on designs below 90 nm. The AEC/APC Symposium session will feature preview presentations from its upcoming symposium, taking place Sept. 30-Oct. 5 in Westminster, Colo. Additionally, ISMI's session on manufacturability will feature chipmaker visions for the future of manufacturing technologies, emphasizing topics of importance for manufacturing success. Finally, the TIS 2006 winners in e-manufacturing will present on the TechXPOT stage, including Luminescent Technologies, Petersen Advanced Lithography, Seaware Technologies and Straatum.

The Emerging Technologies TechXPOT is focused on nanotech, MEMS and energy, including solar and fuel cells. "We're introducing a new segment," Sheet said. "The rationale behind each of those selections is either from a market development standpoint or a technology standpoint. There are some elements that are synergistic with semiconductor manufacturing. What we're really trying to do is bring in new people and new companies into the show so that they can gain an awareness of our industry and the capabilities that exist, and also for them try to find new leads, new partners and highlight some of these innovations so that there can be a clear connection between some of these sectors and our sector."

Sheet said SEMI is working with a number of partners in the emerging technology area. "We're working with the U.S. Fuel Cell Council and the California Fuel Cell Partnership on fuel cells. We're working with two solar groups: the Solar Electric Industries Association and the Solar Electric Power Association. They actually have a solar conference that will be in San Jose in October, and they are a content partner and are going to do a preview of their conference at our TechXPOT. We've got a section of time blocked off for solar presentations and similarly weren't going to do that on the fuel cell area too."

She also said that they are working with a MEMS industry group on the MEMS side to help build SEMICON West into a commercial platform for MEMS companies. "A number of the MEMS exhibitions that are in place around the world have an academic focus, and many of the MEMS exhibitors have said they really want us to build SEMICON West into the commercial MEMS platform. That's why we're working with the MEMS industry group on that." In addition, this TechXPOT is going to have two fuel cell vehicles and a fueling station, courtesy of Ford, Toyota, Air Products and Proton Energy, which are all members of the California Fuel Cell Partnership. Finally, there will be a Segway demonstration area.

For the Test, Assembly and Packaging TechXPOT, SEMI has partnered with MEPTEC, which has organized two sessions: a packaging roadmap from the user's perspective, and another on materials for packaging. An additional session will address the lead-free challenge. Also featured will be a display by Portilligent, which tears apart systems to see which chips are used.

 

International Technology Roadmap for Semiconductors (ITRS) Conference

Taking place during SEMICON West 2006 will be the ITRS annual public conference, where leading industry experts review the roadmap. This conference offers the latest updates to the 2005 ITRS, and looks for input for the technical working groups. Audience members will be asked for their thoughts on the challenges our industry is facing, as well as ways to keep the industry on its historic growth trends. The following areas will be covered during the conference:

  • Emerging research devices
  • Emerging research materials
  • Metrology
  • Lithography
  • Front-end processes
  • Interconnects

The conference will take place from 8 a.m. to 5:30 p.m. Wednesday, July 12, at the San Francisco Marriott Hotel. An ITRS/Sematech-sponsored reception will follow. Visit http://public.itrs.net for more information and to register.



 

Executive Viewpoints

Dwain A. Aidala, President & COO, sp3 Diamond Technologies Inc.

Although the general-purpose microprocessor manufacturers have moved from single-core to multicore designs as a way to work around thermal barriers to performance, the reality is that this is just a temporary fix. As we all know, the continued drive to smaller geometries and higher performance will continue to accelerate power densities, making device-level thermal management a key future limiter to active device performance. This is not only the case for CMOS devices, such as microprocessors, graphics processors and chip-scale packaging. Heat is even more of near-term issue for III-V GaAs and GaN RF and power devices.

The 2005 ITRS, in its emerging materials document, identifies several materials-based thermal management approaches: silicon on diamond (SoD); silicon on silicon carbide; silicon on aluminum oxide on silicon; and isotropically pure silicon. I expect SEMICON West 2006 attendees to have the opportunity to learn more about the transition of some of these approaches from development to scalable productization. The ITRS states, "It would be favorable to have diamond and SiC regions incorporated into chip architectures for thermal management reasons." SEMICON West attendees will be exposed to a SoD product and the manufacturing equipment capable of providing SoD wafers from 100 to 300 mm.

This scalable SoD capability is an item to watch for at SEMICON West, since they will prove to be the enablers of the traditional and continuing path of device and linewidth shrinks. The chip can only get so hot!

Arthur W. Zafiropoulo, Chairman & CEO, Ultratech Inc.

In a world where consumers demand greater functionality and power efficiency in ever-shrinking electronic devices, one thing is clear: innovative chip-manufacturing technologies are needed to break through the barriers and enable future advances. To ensure success, equipment manufacturers must develop technologies that provide extendibility to meet customers' roadmap requirements for multiple device generations while enabling the continuation of Moore's Law.

Today, a company's success is directly proportional to the strength of its customer relationships. Equipment manufacturers depend on knowing their customers' requirements to fuel continued innovation and ensure their technologies fit customers' product roadmaps. Clearly, there are few benefits to bringing technologies to the marketplace before customer demand dictates their implementation. This year's SEMICON West show will display the latest technology innovations, all of which will be the result of each exhibiting company's strong customer relationships.

Phil Dembowski, Global Market Manager, Semiconductor Fabrication Materials, Dow Corning

Low-k dielectrics have now been widely adopted at the 90 nm technology node, with most customers extending tried-and-true CVD-based SiCOH films to 65 nm and beyond. Most industry insiders expect that the 45 nm node will be the first to see adoption of a porous dielectric material with a k value of 2.5. Even though spin-on porous materials had an early technical lead, porous CVD films have caught up and are now the more likely technology to be put into production.

In the transistor area, much of the industry is talking about the use of strain engineering to increase carrier mobility in the channel. A number of different strain-inducing technologies can be combined to significantly improve performance of the next-generation transistor. This opens up opportunities for new silicon-based CVD precursors that can deposit silicon nitride, silicon oxide and silicon germanium at lower temperatures and with specific stress profiles. The implementation of strain engineering at the 45 nm technology node is also likely to delay the use of high-k and metal gates at least a few more years to the 32 nm node.

David Haynes, Director of Sales & Marketing, Surface Technology Systems

Since last year's SEMICON West, the MEMS market has gained considerable momentum with the emergence of a number of high-volume applications and continued interest in the development of a wide array of new products. This year, although the market for established automotive products continues to grow, it is consumer applications that are the key market drivers, and we expect to see a great deal of activity in this area, with MEMS devices being increasingly used in applications as diverse as mobile phone handsets and toys. A prime example of this is Analog Devices' recent report that it is to supply its ADXL 330 iMEMS acceleration sensors to Nintendo for use in "true to life" video game controllers. Moving forward, STS expects to see continued growth in established technologies, such as MEMS-based displays, inkjet heads, and MEMS sensors including accelerometers, gyroscopes and pressure sensors. We also expect new applications to become established in the marketplace. These include acoustic MEMS devices, such as silicon microphones, RF MEMS, and bioMEMS devices.

For Haynes' thoughts on the advanced packaging industry, see "TAP Trends Push Greater Functionality."

Nick Konidaris, President & CEO, ESI

At SEMICON West 2006, a prevailing trend will be the continued focus on cost-effective innovation, with the chief driver being the consumer applications so predominant in today's electronics industry. There is no slack in the ever-growing demand for smaller, more portable, feature-rich and less costly products — MP3 players, mobile phones, gaming devices, DVD recorders — thanks, in large part, to the youth consumer market. Teenagers' insatiable desire for the latest and greatest means that they have more buying influence than ever before. Consequently, they are playing a major role in shaping the future of the semiconductor industry.

For chip and equipment makers alike, keeping up with this demand requires continual innovation, but equipment makers' focus must be on ensuring their solutions can truly be implemented. Innovation cannot occur in a vacuum; it must result from an environment of interdependence and cooperation between customers and suppliers. This is made even more vital by the increasingly global nature of the industry; in particular, Asia is becoming a major center of activity, making collaboration even more critical.

Another interesting development that will have far-reaching effects on our industry is that, while end-use applications such as consumer products drive requirements for semiconductors, the reverse is also true. Continual advancements in device size, functionality and power consumption are driving other industries to make the most of these devices. It's a mutually influential relationship, with each pushing the other to continue improving. We are seeing this in all areas, such as wireless connectivity — whether at the Bluetooth, Wi-Fi or WiMAX range. These technologies are another key driving force for future semiconductor development and innovation.

As the semiconductor industry matures, its fortunes become tied more closely to those of other industries, such as software. For example, when Microsoft Corp. rolls out Windows Vista, the next generation of the Windows client operating system, this will be a major boost for the memory sector. Why? Every computer will need up to 2 Gb of RAM instead of the 512 Mb they required before. Memory makers will look to their suppliers to help them improve manufacturing efficiencies to accommodate the anticipated jump in demand, ensuring that optimizing device performance and yields remains a top priority.

Todd Miklos, Vice President of Marketing, Advanced Energy Industries Inc.

In recent years, we've seen plenty of commentary about the maturing of the global semiconductor industry, at least in percentage growth and theoretical limits of Moore's Law (again). And we've seen rapidly growing interest in neighboring industries like flat panel display (FPD) and solar. SEMI itself now hosts regional FPD events and, is strengthening its solar focus; SEMICON Europa in April featured a photovoltaic track.

This is a natural progression. Many semiconductor OEMs offer similar technologies for FPD and solar end users. In fact, some companies have seen technological innovations developed for one industry later contribute to the success of customers in another industry.

Capitalizing on such synergies is good business. But the driving force must be relevant to emerging customer needs. Golden opportunities can usually be found with existing customers — those where we have mutually beneficial partnerships — by listening carefully when they discuss new applications and then helping them be successful in their chosen markets. Many of our customers — OEMs and end users alike — leverage their thin-film expertise in equipment design, processes and fab operations across sister industries. Our job is to leverage innovation wherever possible in ways that contribute to our customers' success, as well as our own.

In maturing as well as emerging industries, intelligently focusing on customers is the best business strategy.

Jerry Cutini, President & CEO, Aviza Technology Inc.

At SEMICON West 2006, we expect discussion will focus on how the industry will enable the ongoing innovation required to meet the ever-in- creasing demands for digital electronics; in particular, consumer devices that have feature sets that continue to converge. In support of this, technology and process advancements to allow manufacturing of sophisticated ICs at the 65 and 45 nm and below will draw significant attention, such as the adoption of immersion lithography and atomic layer deposition. General industry and business perspectives, such as funding for increasing R&D efforts, will also be at the forefront of discussions at this year's show.

Strategic collaborative efforts have played a critical role for continuing to fuel innovation in our industry. IC manufacturers and equipment suppliers will use this forum to forge interactive and collaborative relationships. Being able to offer the right combination of hardware, process and technology offerings will help facilitate integration across the supply chain.

Specifically, new materials science and development efforts will be required to continue device scaling. By collaborating strategically, chip manufacturers and equipment makers can have a win-win approach across the electronic value chain to address next-generation manufacturing challenges and develop production-worthy solutions.

Industry observers are pointing to a favorable business outlook for the remainder of 2006 and for 2007. Looking specifically at market segments, DRAM and the increasing demand for flash are driving these IC makers to add capacity. Asia, specifically China, will continue to be a region that gains the attention of equipment makers. As with any maturing industry, consolidation throughout the electronics value chain will inherently continue. The companies that will surface above the rest are those that offer unique business models to adapt to customers' rapidly changing needs.

Timothy P. Tobin, President & CEO, Entrepix Inc.

Consistent macroeconomic trends are evident from three primary drivers — the ongoing maturation of the semiconductor industry; the influence of China as a cost benchmark and market presence that is also dedicated to developing technology; and the ever-present governing principle, Moore's Law.

While the latter will always keep this a high-technology industry, the two prior influences create a commodity nature to semiconductor products. A maturing market means a consolidation of players, thus the stakes become higher. With higher stakes comes fierce competition between entities dedicated to market dominance and, therefore, increased margin pressure. This forces companies to approach all aspects of their business from a highly strategic basis first, then from an operational one. Executives and management teams from the most competitive corporations assess and clearly identify their internal core competencies, then look to optimize financial performance by using complementary resources from outside service providers.

In response to these needs, a supply chain of flexible, reliable, long-term solutions has developed. This can be seen in everything from construction, relocation and equipment refurbishment services to sub-fab and facilities management to complete fabrication or single-process module foundries, such as CMP, ion implant or epitaxial growth. Now, more than ever before, companies use outsource providers to reduce costs and risks while accelerating time to revenue both for capturing increased demand on current products and for faster introduction of next-generation advancements. From the world's largest IDMs to startup design houses, nanotechnology-scale IC fabricators to multi-micron MEMS producers, these trends are present and increasing rapidly across virtually all market segments.

Jeff Spiegelman, President, RASIRC

As we continue down the roadmap toward smaller feature sizes, the value and significance of each individual molecule increases rapidly. Processes such as atomic layer deposition (ALD) and ultrathin oxides are already working on a molecular scale. To successfully manufacture devices at the molecular level, control of unwanted molecular contamination will move to the forefront in yield management. Not only will purity of gas, chemicals and rinse water need tighter control, but the entire processing life of the wafer's ambient environment will also have to be controlled and monitored. This is generating a number of new contamination control products for process, storage and transportation.

If we focus on contamination from process materials, then we see that new device structures require chemistries that are safer. This has led chemical suppliers to provide low vapor pressure gases that are liquid or solid at room temperature, which makes them more difficult to purify. Bulk gas purification technology no longer applies, since the chemical is in a liquid state until vaporized at point of use. Liquid purification techniques are not yet available. Purification of the vapors is problematic because of condensation in the purifier.

Heating to prevent condensation reduces purifier efficiency or capacity significantly.

To meet these chemical delivery challenges, new flow control and purification devices are being developed, such as advanced designs of vaporizers and liquid flow controllers. Look for technologies that integrate purification, vaporization and flow control to ensure the correct molecules get to the process chamber and impurities are excluded.

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